Methods for processing denim

ABSTRACT

Methods for processing denim are provided. An initial fabric is abraded by passing the initial fabric through an abrader at a first predetermined speed, thereby obtaining a pre-washed fabric with an abraded texture. The abrader comprises one or more sanding boards, where each respective sanding board has a respective diamond surface that contacts the initial fabric while spinning about a respective axis at the respective center of the respective sanding board during the abrading. The pre-washed fabric is then washed with an ozone composition, thereby obtaining an ozone washed fabric.

CROSS REFERENCE TO RELATED PATENT APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 63/034,323 entitled “PROCESS FOR DYEING AND WASHING DENIM,” filed Jun. 3, 2020, which is hereby incorporated by reference.

TECHNICAL FIELD

This specification describes using abrasion and washing to produce denim fabric with varying amounts of color fade.

BACKGROUND

The production of denim clothing faces challenges because it is environmentally costly at multiple stages of the process. For example, production of denim clothing requires a fabric dyeing (indigo dying) process. This dying process itself typically requires large amounts of water and reagents. Under conventional methods of indigo dyeing, whether done continuously or in closed batch, when the denim is removed from the dyebath, the leuco indigo used in the dying process almost instantaneously reacts with oxygen in the air and initially turns green (the combination of partial blue and partial yellow) as it transitions to the insoluble, intensely colored blue indigo that is the hallmark of denim fabric. Current fabrication methods leave significant amounts of the dye liquor on the surfaces of textile substrates. This unavoidably oxidizes and leaves behind considerable surface indigo that must be removed by washing. The waste water from this washing is often polluted post-manufacturing and requires processing. In addition, after dyeing and cut- and trim processing of fabric, to produce clothing with desired appearance and feel (e.g., slightly or heavily worn), it is typical practice to wash the clothing (e.g., stone washing, acid washing, and/or enzyme washing) for varying lengths of time, which requires even more water and power.

As companies increasingly seek to offer products with improved sustainability, reduction in water and energy usage is becoming more important. However, there remains a need for these products to deliver equal or better performance than conventionally washed and dyed alternatives at a comparable price point.

Given the need for production methods with lower environmental impact, improved methods of dyeing and preparing fabric for the production of clothing are needed in the art.

SUMMARY

The present disclosure addresses the shortcomings identified in the background by providing improved methods for converting dyed fabric into fabric. Such fabric can then be used to make articles of clothing.

In one aspect, a method for processing denim is provided. The method comprises abrading an initial fabric by passing the initial fabric through an abrader at a first predetermined linear speed, thereby obtaining a pre-washed fabric with an abraded texture. The abrader comprises one or more sanding boards, where each respective sanding board in the one or more sanding boards has a respective surface that contacts the initial fabric while spinning about a respective axis at a respective center of the respective board during the abrading. The method further comprises washing the pre-washed fabric with an ozone composition, thereby obtaining an ozone washed fabric. The method optionally further comprises using the ozone washed fabric to produce the article of clothing.

In some embodiments, the ozone washed fabric is denim.

In some embodiments, the method further comprises, prior to the abrading, dyeing a yarn comprising a plurality of textile fibers with a blue dye by coating a surface of the yarn with the blue dye and weaving the yarn to form the initial fabric. In some embodiments, the blue dye is an indigo dye, a sulphur dye, or a combination of an indigo and a sulphur dye.

In some embodiments, the plurality of textile fibers is natural fibers, regenerated fibers, or synthetic fibers. In some embodiments, the plurality of textile fibers comprises flax, kapok, hemp, jute, ramie, sisal, abaca, coir, or Pineapple fiber. In some embodiments, the plurality of textile fibers comprises rayon, polyester, polyamide, aramid, olefin, elastomer, or acrylic. In some embodiments, the plurality of textile fibers comprises elastic polyurethane fibers. In some embodiments, the plurality of textile fibers comprises stable fibers, filaments, or tow. In some embodiments, the plurality of textile fibers are round, dog bone shaped, trilobal, multilobal, serrated, band, triangular, oval, or hollow shaped. In some embodiments, the plurality of textile fibers is blended fibers.

In some embodiments, the yarn is monofilament yarn or multifilament yarn. In some embodiments, the yarn is staple or spun yarn. In some embodiments, the yarn is a covered yarn. In some embodiments, the covered yarn comprises a core and a wrap. In some embodiments, the core is an elastomeric fiber core, an elastic core, a SPANDEX monofilament core, or a LYCRA core. In some embodiments, the wrap is a filament-yarn wrap, a spun-yarn outer cover, a spun-yarn wrap, or a rat cross-sectional filament wrap.

In some embodiments, the dyeing is performed using foam indigo dye in the presence of nitrogen.

In some embodiments, each respective surface of each sanding board in the one or more sanding boards spins about the respective axis of the respective sanding board at the respective center of the sanding board at a rate of between 100 and 3000 revolutions per minute, a rate of between 500 and 2800 revolutions per minute, or a rate of between 800 and 2500 revolutions per minute.

In some embodiments, each respective surface of each sanding boards in the one or more sanding boards is cylindrical and has a diameter of between 2 and 20 inches. In some embodiments, each respective surface of each sanding boards in the one or more sanding boards is electroplated at a specified grit. In some embodiments, the specified grit is between grit 400 and grit 2400 Fédération Européenne des Fabricants de Produits Abrasifs F standard (FEPA F) for sharpening stones and wheels. In some embodiments, the one or more sanding boards comprises between 3 and 30 sanding boards.

In some embodiments, the first predetermined linear speed is between 10 meters per minute and 100 meters per minute.

In some embodiments, the abrading and washing cause the pre-washed fabric to exhibit a predetermined amount of color fade relative to the initial fabric.

In some embodiments, the predetermined amount of color fade causes the ozone washed fabric to be dark indigo, medium indigo, or light indigo.

In some embodiments, the article of clothing is a pair of denim jeans. In some embodiments, the article of clothing is a denim shirt, a denim dress, a denim skirt, or a denim handbag.

In some embodiments, the ozone composition is between 5 g/Nm³ ozone and 100 g/Nm³ ozone.

In some embodiments, the ozone washed fabric has a width of between 80 centimeters and 400 centimeters. In some embodiments, the ozone washed fabric has a length of at least 50 meters. In some embodiments, the ozone washed fabric has a length of at least 100 meters. In some embodiments, using the ozone washed fabric to produce the article of clothing comprises cutting, making, and trimming with the ozone washed fabric to form the article of clothing.

In some embodiments, the method further comprises washing and drying the yarn after the dyeing and before the weaving or abrading. In some embodiments, the method further comprises agitation washing the article of clothing, and drying the article of clothing. In some embodiments, the agitation washing of the article of clothing comprises a sonic washing in a water bath.

In some embodiments, the method further comprises patterning the article of clothing with a laser to produce one or more laser designs within the article of clothing. See, Tarhan and Sariisik, 2009, “A comparison among performance characteristics of various fading processes,” Text. Res. J. 79(4), pp. 303-309, which is hereby incorporated by reference. In some embodiments, the patterning is done before the agitation washing of the article of clothing. In some embodiments, the patterning is done after the agitation washing and the drying of the article of clothing.

As disclosed herein, any embodiment disclosed herein when applicable can be applied to any aspect.

Additional aspects and advantages of the present disclosure will become readily apparent to those skilled in this art from the following detailed description, where only illustrative embodiments of the present disclosure are shown and described. As will be realized, the present disclosure is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the disclosure. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.

INCORPORATION BY REFERENCE

All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference in their entireties to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference. In the event of a conflict between a term herein and a term in an incorporated reference, the term herein controls.

BRIEF DESCRIPTION OF THE DRAWINGS

The implementations disclosed herein are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings. Like reference numerals refer to corresponding parts throughout the several views of the drawings.

The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.

FIGS. 1A and 1B illustrate examples of abrasion of fibers comprising the pre-washed fabric, in accordance with some embodiments of the present disclosure.

FIGS. 2A, 2B, 2C, 2D, 2E, 2F, 2G, and 2H, collectively illustrate flowcharts of methods of processing denim, in accordance with some embodiments of the present disclosure, in which optional steps, embodiments, specifications, or features are indicated by dashed boxes.

FIGS. 3A, 3B, and 3C each illustrate microscopic images of finished fabric (e.g., at different stages of production), in accordance with some embodiments of the present disclosure.

FIG. 4 illustrates types of covered yarn that can be manufactured using the disclosed systems and methods, where the types of covered yarn are disclosed in the prior art.

FIG. 5 illustrates a twill weave in accordance with the prior art.

FIG. 6 illustrates how the coupling of abrasion followed by ozone washing creates denim that looks like it has been processed in denim laundry but has now been created in the fabric form, in accordance with an embodiment of the present disclosure.

FIG. 7 illustrates an unwashed garment that has not been subjected to fabric abrasion (left) and an unwashed garment that has been subjected to fabric abrasion (right), in accordance with an embodiment of the present disclosure.

FIG. 8 illustrates the garments of FIG. 7 after they have been ozone washed in accordance with an embodiment of the present disclosure.

FIG. 9 illustrates a schematic of a NB-MATCHPOINT GMB diamondTec finishing machine in accordance with the prior art.

FIG. 10A illustrates a sanding board in the form of a slat roller in accordance with the prior art.

FIG. 10B illustrates a sanding board in the form of a cylinder roller in accordance with the prior art.

DETAILED DESCRIPTION

The systems and methods described herein provide improved processes for producing articles of clothing with lower environmental impact. In particular, by the combination of a foam indigo dyeing method, an abrasive indigo removal method, and an ozone-washing method, the disclosed systems and methods require less water usage and energy relative to conventional clothing fabrication techniques. In addition, the systems and methods described herein produce articles of clothing with higher durability and size consistency (e.g., stone washing and other conventional washing methods typically reduce the structural integrity of articles of clothing).

Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be apparent to one of ordinary skill in the art that the present disclosure may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

The implementations described herein provide various technical solutions for training a reference model to determining a tumor fraction for a subject.

Definitions

As used herein, the term “denim” refers to a twill-woven cotton or primarily cotton textile fabric produced from yarn comprising a plurality of fibers (e.g., a warp-face fabric). In some embodiments, denim comprises warp yarn that is dyed with indigo dye, sulphur dye, or a combination of indigo and sulphur dye and weft yarn that is undyed (e.g., grey). In some embodiment denim is a “right-handed warp-face uneven twill” in which the warp yarns are colored with white filling yarns (e.g. weft). In such embodiments, the warp-faced twill causes the colored warp yarns to be predominant on the face and the white filling yarns to be predominant on the back. In typical embodiments, the warp yarns are indigo dyed, created the fabric in “blue jeans.” In some embodiments, the denim fabric is made out of 2/1 twills.

As used herein, the term “indigo” refers to either naturally obtained or synthetically produced indigo, having the IUPAC name 3H-indol-3-1, 2-(1,3-dihydro-3-oxo-2H-indol-2-ylidene)-1,2-dihydro- which has the structure:

Naturally occurring indigo is obtained from sources such as I. tinctoria (also known as Indigofera sumatrana), Strobilanthes cusia, I. suffruticosa, Indigofera arrecta, ls. tinctoria (woad) and Polygonum tinctorum (dyer's knotweed). As used herein, the term “indigo” further refers to indigo that has been converted to the water soluble form leuco indigo (e.g., by fermentation or bacterial reduction, chemical reduction, electrochemical reduction, catalytic hydrogenation, or electrocatalytic hydrogenation. See, Woodhead Publishing Series in Textiles: Number 164 Denim, Manufacture, Finishing and Applications, ed. Roshan, P., Elsevier, Cambridge UK, 2015, Section 3.7, which is hereby incorporated by reference. For instance, in some embodiments, the indigo is reduced to Leuco indigo using sodium hydrosulphite, hydroxyacetone, acetoin, glutaroin, adipoin, and/or α-hydroxybarbonyls. In some embodiments, the indigo is reduced to Leuco indigo using a combination of glucose and NaOH. In some embodiments, the indigo is reduced to Leuco indigo using thiourea dioxide, formamidmesulphhamic acid. In some embodiments, the indigo is reduced to Leuco indigo using iron(II) salt complexed with tartaric acid, citric acid or triethanolamine along with NaOH.

As used herein, the term “grit” refers to the abrasive properties of a surface. For example, a lower grit number (e.g., grit 40) refers to a coarse, more abrasive surface and a higher grit number (e.g., grit 1000) refers to a fine, less abrasive surface. An abrasive surface can be produced by adhering grit particles to the surface (e.g., the surface is coated with grit particles of a predetermined size at a predetermined density, where the predetermined size and density of the particles define the grit value of the surface). Typically, particles of a higher predetermined size result in a lower grit number (e.g., the density of particles on the surface will necessarily be lower) and particles of a smaller predetermined size results in a higher grit value (e.g., a higher density of particles can be fit onto the surface). In some embodiments, grit particles comprise aluminum oxide, garnet, emery, silicon carbide, aluminum-zirconia, chromium(III) oxide, ceramic aluminum oxide, diamond, or a combination thereof. As used herein, grit numbers are given in units of FEPA-F.

As used herein, the term “abrade” or “abrasion” refers to removing dye molecules from textile fibers. For example, FIG. 1A represents cross-sections of a dyed fiber 102 before and after abrasion 108 performed in accordance with embodiments described herein. Prior to abrasion, fiber 102 has a mostly uniform coating of dye 104 (e.g., a layer of indigo dye adhered to the fiber material). After abrasion (e.g., after exposure to one or more diamond sanding boards), the dye layer 106 is non-uniform (e.g., has been ‘nicked’ at multiple locations). The diameter and extent of the abrasion of the dye layer determines the extent of the color fade in the prewashed fabric (e.g., higher abrasion results in more color fade). FIG. 1B illustrates an example of abrading a fabric 110 using one or more sanding boards 112. In some embodiments, each respective sanding board of the one or more sanding boards (e.g., sanding boards 112 a-112 d) is electroplated with diamond at a specified grit (e.g., grit particles 114). In some embodiments, each respective sanding board of the one or more sanding boards has the same grit. In some embodiments, a subset of the sanding boards has a different unique grit (e.g., sanding board 112 a may have a different grit from that of sanding board 112 d).

As used herein, a “twill weave” is a weave that is normally woven on four or more shafts. In a twill weave, each warp or weft yarn floats over two or more weft or warp yarns, with a progression of interlacing by one to the left or right, forming a distinct diagonal line as illustrated in FIG. 5. Though a twill weave can be woven on three shafts, four or more shafts are normally used. Twill weave have a technical face and back cloth; the face is the side that shows the pronounced diagonal line. Twill weaves have two classifications, uneven or balanced. Uneven twills are those in which the warp comes to the surface to either a greater or lesser extent than does the weft. If the warp predominates on the face, the weave is called warp twill. If the filling predominates, it is called weft twill. Balanced twills are those in which the warp and weft come to the surface to the same extent. Because there are more weft yarns than warp in twill-weave structures, the fabrics produced are heavier in with than plain-weave fabrics. As twill-weave fabrics have textured and patterned surfaces they are not often used for printed fabrics. Due to the strength of twill-weave fabrics, they are often used for work apparel or upholstery, as well as denim jeans. Fewer interlacings allow the yarns to move freely and fabrics are more pliable, lustrous and softer than plain-weave fabrics; they also recover better from wrinkles than plain-weave fabrics. see Textiles and Fashion Materials, Design and Technology, Rose Sinclair ed., Elsevier Ltd. 2015, Oxford UK, which is hereby incorporated by reference, including, in particular, pp. 273-274.

The terminology used herein is for describing particular cases only and is not limiting. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Furthermore, to the extent that the terms “including,” “includes,” “having,” “has,” “with,” or variants thereof are used in either the detailed description and/or the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.”

Several aspects are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide a full understanding of the features described herein. One having ordinary skill in the relevant art, however, will readily recognize that the features described herein can be practiced without one or more of the specific details or with other methods. The features described herein are not limited by the illustrated ordering of acts or events, as some acts can occur in different orders and/or concurrently with other acts or events. Furthermore, not all illustrated acts or events are required to implement a methodology in accordance with the features described herein.

Exemplary Methods

FIG. 2 illustrates an overview of the techniques in accordance with some embodiments of the present disclosure. In the described embodiments, a method for processing denim is provided.

Block 202.

Referring to block 202, of FIG. 2A, the present disclosure is directed to methods for processing denim.

Block 204-244.

Referring to optional block 204, in some embodiments a yarn comprising a plurality of textile fibers is dyed with a dye by coating a surface of the yarn with the dye.

In some embodiments, the dye is blue. In some embodiments, the blue dye is indigo dye. In some embodiments, the blue dye is another type of dye (e.g., another shade of blue or another color than blue). Dyed yarn prior to abrading is illustrated in FIG. 3A, where individual fibers are heavily coated (e.g., are darker in appearance).

In some embodiments, the dyeing is optionally performed using foam indigo dye in the presence of nitrogen. For example, in some embodiments, any of the dyeing methods described in U.S. Pat. No. 1,061,929, entitled “Indigo dyeing process and apparatus and indigo dyed yarns and fabrics made thereby,” filed Sep. 12, 2016, which is herein incorporated in its entirety, can be used to dye the yarn comprising the plurality of textile fibers.

In some embodiments, rather than foam dyeing, conventional dyeing is used. In some embodiments, the dyeing is performed using an indigo rope range. In some such embodiments, the yarn is in the form of ropes and between one and 48 ropes are dyed at one time. The dyeing at may be practiced using a wide variety of dyeing systems, such as vat, sulfur, reactive, napthol, padazoic, directs, and pigment, and are not limited to any one particular system. In some embodiments, the dyeing is performed using a Smartec rope dyeing machine such as the Smartec model LHJ3689.

The process of dyeing the yarn with foam indigo dye or by conventional dyeing processes, as performed in accordance with some embodiments herein, results in a layer of indigo molecules coating textile fibers (e.g., as illustrated in FIG. 1A).

In some embodiments, the use of foam dye enables the dye to adhere to fibers more efficiently (e.g., the fibers become coated with dye more quickly or easily). As described in U.S. Pat. No. 1,061,929, this can result in a thinner layer of dye, which makes downstream processes such as obtaining color fade easier.

In some embodiments, the dye that is used is DyStar Indigo VAT 40% Solution (DyStar Singapore Pte Ltd., Singapore). See, the Internet dystar.com/denim-solutions/. This product has an Indigo concentration of 40% by weight and an alkali concentration of 9% by weight.

In some embodiments, the dye is an indigo dye or a sulphur dye, the plurality of textile fibers is natural fibers, regenerated fibers, or synthetic fibers, the plurality of textile fibers comprises cotton fibers. In some embodiments, the plurality of textile fibers comprises flax, kapok, hemp, jute, ramie, sisal, abaca, coir, or Pineapple fiber. In some embodiments, the plurality of textile fibers comprises rayon, polyester, polyamide, aramid, olefin, elastomer, or acrylic. In some embodiments, the plurality of textile fibers comprises elastic polyurethane fibers. In some embodiments, the plurality of textile fibers comprises stable fibers, filaments, or tow. In some embodiments, the plurality of textile fibers is round, dog bone shaped, trilobal, multilobal, serrated, band, triangular, oval, or hollow shaped. In some embodiments, the plurality of textile fibers is blended fibers. In some embodiments, the plurality of textile fibers is cotton blended with lycra, polyester, lyocell, wool, flax, or hemp. In some embodiments, the plurality of textile fibers comprises Gossypium hirsutum cotton, Gossypium barbadense cotton, Gossypium arboreum cotton, or Gossypium herbaceum cotton.

In some embodiments, the plurality of textile fibers have a length in the range of 10-65 mm, a fitness in the range of 1.2-2.8 dtex, a dry tenacity in the range of 1.9-3.1 cN/dtex, a dry breaking extension in the range of 7 percent to 10 percent, a moisture regain of about 8.5 percent, and/or a density of 1.5 to 1.54 g/cm³. In some embodiments, the plurality of textile fibers has a minimum stable length of 28 mm. In some embodiments, the yarn is monofilament yarn or multifilament yarn. In some embodiments, the yarn is staple yarn or spun yarn. In some embodiments, the yarn is a denim warp yarn having a count of between Ne 4.0 and Ne 12.5. In some embodiments, the yarn is a denim warp yarn having a count of between Ne 12.5 and Ne 30.0. In some embodiments, the yarn is produced by ring spinning, compact spinning, or rotor spinning.

In some embodiments, with regard to block 208, the plurality of textile fibers comprises natural fibers, regenerated fibers, synthetic fibers, or some combination thereof. In some embodiments, the plurality of textile fibers comprises cotton fibers. In some embodiments, the plurality of textile fibers consists of cotton fibers. In some embodiments, the plurality of textile fibers comprises flax, kapok, hemp, jute, ramie, sisal, abaca, coir, Pineapple fiber, or some combination thereof. In some embodiments, the plurality of textile fibers comprises rayon, polyester, polyamide, aramid, olefin, elastomer, acrylic, or some combination thereof. In some embodiments, the plurality of textile fibers comprises elastic polyurethane fibers. In some embodiments, the plurality of textile fibers comprises stable fibers, filaments, tow, or some combination thereof. In some embodiments, the plurality of textile fibers is round, dog bone shaped, trilobal, multilobal, serrated, band, triangular, oval, or hollow shaped. In some embodiments, the plurality of textile fibers is blended fibers.

In some embodiments, dying of the yarn is performed using rope, slasher or loop dyeing methods. In some embodiments, the yarn is dyed using a solution that has an indigo concentration of between 1.2 percent and 5 percent. In some embodiments the yarn is dyed in the presence of caustic soda and sodium hydrosulphite. In some embodiments, the dying process, with the indigo first being reduced to soluble Leuco indigo and exposed to the yarn and then oxidized back to the original insoluble form, being repeated several times to obtain the desired shade. In some embodiments, such dying takes place in fermentation vats, chemical vats, or hydrosulphite vats.

In some embodiments, the dying of the yarn with indigo is done using a continuous yarn dyeing technique. In some embodiments, the article of clothing to be manufactured is to be made out of denim that is 100% cotton with a blue face and white back, in which the warp yarns of the fabric are indigo dyed and the weft yarns are non-dyed cotton.

In some such embodiments, the dyeing of the warp yarns of the fabric is done continuously using rope dyeing, slasher dyeing, or loop dyeing. See, Section 4.3.2 of Woodhead Publishing Series in Textiles: Number 164 Denim, Manufacture, Finishing and Applications, ed. Roshan, P., Elsevier, Cambridge UK, 2015, which is hereby incorporated by reference.

In an exemplary rope dyeing technique, 350-400 warp threads are bound on a ball-warper machine to very thick cables of 10,000-25,000 m in length or greater. Generally 12-36 such cables are fed into a scouring bath containing wetting agents, detergents and sodium hydroxide. The scouring baths are used to remove impurities such as dirt, naturally occurring wases, etc. Then the cables are fed into one or more water rising baths. After that the cables are dipped into a bath of leuco indigo with an immersion time of 12-20 seconds, and then are squeezed to give up 79%-80% wet pick-up after each dip, followed by exposure to air (e.g., at least 80 seconds) for oxidation, multiple times. The cables of yarn are then washed in water baths to eliminate non-fixed dye. Example rope ranges suitable for rope dying are made by Morrison Textile Machinery, USA (e.g., Spectrum Indigo Rope Dye Range), Master S.r.l., Italy, (e.g., IndigoRope), Karl Mayer Textilmashinefabrik GmbH, Germany (e.g., Indig-O-Matic IOM-R), Looptex Company, Italy (e.g., Rope Dye), Komatsubara Iron Works Ltd., Japan, and Smartec Machinery & Engineering, China (e.g., Model LHJ3689).

In an exemplary slasher dyeing technique, section beams of warp yarn are forced into a sheet of yarns (approximately 3000-5000 yarns), which is first fed into a scouring section to remove natural impurities. Then the sheet passes through multi-dip/nip indigo dyeing section with an immersion time of 4-15 seconds in order to achieve fairly deep shades followed by oxidation for at least 45 seconds. After, rinsing and sizing, the warp sheet is directly processed and then sent to a weaving section for conversion to fabric. Example slasher dyeing machines suitable for slasher dying are made by Morrison Textile Machinery, USA, Master S.r.l., Italy, (e.g., IndigoFlow, and IndigoGenius); Karl Mayer Textilmashinefabrik GmbH, Germany (e.g., Indig-O-Matic IOM-S); Looptex Company, Italy; Benninger AG, Switzerland (e.g., Ben-Indigo); Texima S.A. Industria de Maquinas, Brazil (e.g., Multicaixas slasher dyeing machine); Memnum Makina, Turkey; and Jupiter Comtex Pvt Ltd., India.

In an exemplary loop dyeing technique, the yarns are dyed in only a single dyeing bath with one squeezing unit, after passing through pre-treatment boxes. When the yarns exit the dyeing bath, instead of moving forward, the yarns are passed back into the dye bath for another dye passage in a continuous loop. According to the desired shade, the yarns can make multiple loops through the dye bath, after which they are passed through wash boxes and then onto drying cylinders. The loop dyeing technique is offered in machines sold by Looptex, under the Loopdye brand.

Block 246.

Referring to block 246 of FIG. 2C, in some optional embodiments, the yarn, and/or subsequent fabric produced by weaving of one or more yarns, is a blend of X percent cotton and Y percent elastane, where X and Y sum to 100 percent and X is in the range of 50 percent to 99 percent. In some such embodiments, X is in the range of 60 percent to 98 percent. In some such embodiments, X is in the range of 70 percent to 96 percent. In some such embodiments, X is in the range of 80 percent to 94 percent. In some such embodiments, X is in the range of 88 percent to 92 percent.

Block 248.

Referring to block 248 of FIG. 2C, in some optional embodiments, the yarn, and/or subsequent fabric produced by weaving of one or more yarns, is a blend of X percent cotton, Y percent elastane, and Z percent Lycra, where X, Y, and Z sum to 100 percent and X is in the range of 50 percent to 94 percent. In some such embodiments, X is in the range of 70 percent to 96 percent. In some such embodiments, X is in the range of 80 percent to 94 percent. In some such embodiments, X is in the range of 88 percent to 92 percent. In some such embodiments, Y is in a range of 1 percent to 25 percent, 2 percent to 20 percent, 3 percent to 15 percent, 4 percent to 10 percent, or 5 percent to 8 percent. In some such embodiments, Z is in the range of 88 percent to 92 percent. In some such embodiments, Y is in a range of 1 percent to 25 percent, 2 percent to 20 percent, 3 percent to 15 percent, 4 percent to 10 percent, or 5 percent to 8 percent.

Block 250.

Referring to block 250 of FIG. 2C, in some optional embodiments, the yarn, and/or subsequent fabric produced by weaving of one or more yarns, is a blend of X percent cotton, Y percent polyester, and Z percent Lycra, where X, Y, and Z sum to 100 percent and X is in the range of 50 percent to 94 percent. In some such embodiments, X is in the range of 70 percent to 96 percent. In some such embodiments, X is in the range of 80 percent to 94 percent. In some such embodiments, X is in the range of 88 percent to 92 percent. In some such embodiments, Y is in a range of 1 percent to 25 percent, 2 percent to 20 percent, 3 percent to 15 percent, 4 percent to 10 percent, or 5 percent to 8 percent. In some such embodiments, Z is in the range of 88 percent to 92 percent. In some such embodiments, Y is in a range of 1 percent to 25 percent, 2 percent to 20 percent, 3 percent to 15 percent, 4 percent to 10 percent, or 5 percent to 8 percent.

Block 254-260.

Referring to block 254 of FIG. 2D, in some embodiments, the yarn is a covered yarn. In some such embodiments, the covered yarn comprises a core and a wrap. In some such embodiments, the core is an elastomeric fiber core, an elastic core, a SPANDEX monofilament core, or a LYCRA core. In some such embodiments, the wrap is a filament-yarn wrap, a spun-yarn outer cover, a spun-yarn wrap, or a rat cross-sectional filament wrap.

In some embodiments, the covered yarn comprises a core that is completely covered by fiber or another yarn (wrap). With reference to FIG. 4, in some embodiments, the core is an elastomeric fiber core (e.g., Panel A), an elastic core (e.g., Panel B), a hard-multifilament core (e.g., Panel C), a SPANDEX monofilament core (e.g., Panel D), or a LYCRA core. In some embodiments, the wrap is a filament-yam wrap (e.g., panel A), a spun-yam wrap (e.g. panel B), a spun-yarn outer cover (e.g., panel C), or a rat cross-sectional filament wrap (e.g., panel D). For more information on covered yarns, see Textiles and Fashion Materials, Design and Technology, Rose Sinclair ed., Elsevier Ltd. 2015, Oxford UK, which is hereby incorporated by reference, including, in particular, pp. 175-176.

In some embodiments, the yarn is produced by ring spinning, compact spinning, and/or rotor spinning. Exemplary ring spinning techniques are disclosed in Wulfhorst et al., 2006, Textile Technology, Hanser Publishers, Munich, Germany as well as section 2.5.1 of Woodhead Publishing Series in Textiles: Number 164 Denim, Manufacture, Finishing and Applications, ed. Roshan, P., Elsevier, Cambridge UK, 2015, each of which is hereby incorporated by reference. Exemplary compact spinning techniques are disclosed in Smekal et al., 2001, Air-Com-Tex 700 for compact spinning yarns, Melliand Int. 7(1), 18-19, as well as section 2.5.2 of Woodhead Publishing Series in Textiles: Number 164 Denim, Manufacture, Finishing and Applications, ed. Roshan, P., Elsevier, Cambridge UK, 2015, each of which is hereby incorporated by reference. Exemplary rotor spinning techniques are disclosed in Alagirusamy and Das, 2010, “Rotor Spinning,”Advances in Yarn Spinning Technology, Lawrence, C.A. (Ed.), Woodhead Publishing Ltd., Cambridge, UK, pp. 261-273, as well as section 2.5.3 of Woodhead Publishing Series in Textiles: Number 164 Denim, Manufacture, Finishing and Applications, ed. Roshan, P., Elsevier, Cambridge UK, 2015, each of which is hereby incorporated by reference.

Blocks 262-264.

Referring to block 262 of FIG. 2D, in some embodiments the yarn is weaved to form the initial fabric. Referring to block 264, in some embodiments, the method further comprises washing and drying the yarn after the dyeing and before the weaving (block 262) or abrading (block 266).

In some embodiments, prior to the abrading disclosed below in conjunction with block 266, the method comprises dyeing the yarn comprising a plurality of textile fibers with a blue dye by coating a surface of the yarn with the blue dye, and weaving the yarn to form the initial fabric. In some embodiments, the initial fabric is a 3×1 (3 warp threads for every weft thread) twill weave. In some embodiments, the initial fabric is a 2×1 (2 warp threads for every weft thread) twill weave. In some embodiments, the initial fabric is a plain (one warp thread for every weft thread) weave. In some embodiments, the initial fabric is over 9 Oz per square yard, over 9.5 Oz per square yard, over 10.0 Oz per square yard, or over 10.5 Oz per square yard.

Blocks 266-274.

Referring to block 266 of FIG. 2E, an initial fabric (e.g., a dyed fabric, as illustrated in FIG. 3A) is abraded by passing the initial fabric through an abrader at a first predetermined speed, thereby obtaining a pre-washed fabric with an abraded texture. The abrader comprises one or more sanding boards (e.g., diamond sanding boards). Each respective sanding board in the one or more sanding boards has a respective surface (e.g., face) that contacts the initial fabric while spinning about a respective axis at a respective center of the respective sanding board during the abrading. In some embodiments, the abrader is a MATCHPOINT GMB diamondTec finishing machine. See, https://www.matchpoint-textile.com/english/diamondtec/, which is hereby incorporated by reference. FIG. 9, similar to FIG. 1B, is a schematic of the MATCHPOINT abrader 900. The abrader 900 comprises a plurality of sanding boards (e.g., sanding boards 902-1, 902-2, 902-3, and 902-4). More or fewer sanding boards could be used for the abrader. In the case of abrader 900 of FIG. 9, the one or more sanding boards is four slat rolls 902. Each respective slat roll in the plurality of rolls spins clockwise or counterclockwise with respect to the direction the fabric is passing. In FIG. 9, the fabric direction (first direction) is indicated as traveling from left to right. In the abrader, the spin of each sanding board 902 is independent of the spin of all other sanding boards. Thus, for instance, sanding board 902-1 could spin with the fabric direction (clockwise) while, at the same time, sanding board 902-2 could spin against the fabric direction (counter-clockwise). The spin of a respective sanding board 902 causes the diamond encrusted outer surface of the respective sanding board 902 to rub against the fabric. For instance, referring to FIG. 9, the clockwise or counterclockwise spin of sanding board 902-1 causes each the diamond encrusted slats 912 of the sanding board to contact the fabric. In some embodiments, each sanding board of the abrader is a slat roller as illustrated in FIGS. 9 and 10A. In some embodiments, each sanding board of the abrader is a cylinder roller as illustrated in FIGS. 1B and 10B.

As further illustrated in FIG. 9, the abrader 900 further comprises a plurality of contact rolls 906 that push the fabric against the sanding boards 902 at a predetermined pressure. With reference to block 270, in some embodiments, the pressure applied by each contact roll 906 is between 5 and 60 Kg/cm. In some embodiments, the pressure applied by each contact roll 906 is between 1 and 100 Kg/cm. In some embodiments, the pressure applied by each contact roll 906 is different. In some embodiments, the pressure applied by each contact roll 906 is the same.

As further illustrated in FIG. 9, tension is applied against the fabric by using a pair of double transport rollers 914 are used to control the tension on the fabric while it is being abraded with the sanding boards 902.

In some embodiments, the abrading affects the amount of dye adhering to fibers in the initial fabric (e.g., as shown in FIG. 3B, less dye is present—the fibers appear lighter than in FIG. 3A). For example, FIG. 3C, which is a zoomed-in version of FIG. 3B, illustrates portions of the initial fabric (e.g., 352 and 354) that appear to have had dye mostly or completely removed.

In some embodiments, each respective sanding board in the one or more sanding boards spins about the respective axis (e.g., cylindrical axis) of the respective sanding board at the respective center of the respective sanding board at a rate of between 1000 and 3000 revolutions per minute. In some embodiments, each respective sanding board in the one or more sanding boards spins about the respective axis of the respective sanding board at the respective center of the respective sanding board at a rate of between 200 and 2000 revolutions per minute. In some embodiments, each respective sanding board in the one or more diamond sanding boards spins about the respective axis of the respective sanding boar at the respective center of the respective sanding board at a rate of between 1700 and 1900 revolutions per minute. In some embodiments, each respective sanding board in the one or more sanding boards spins about the respective axis of the respective diamond board at the respective center of the respective sanding board at a rate of at least 200 revolutions per minute, at least 200 revolutions per minute, at least 300 revolutions per minute, at least 400 revolutions per minute, at least 500 revolutions per minute, at least 600 revolutions per minute, at least 700 revolutions per minute, at least 800 revolutions per minute, at least 900 revolutions per minute, at least 1000 revolutions per minute, at least 1100 revolutions per minute, at least 1200 revolutions per minute, at least 1300 revolutions per minute, at least 1400 revolutions per minute, at least 1500 revolutions per minute, at least 1600 revolutions per minute, at least 1700 revolutions per minute, at least 1800 revolutions per minute, at least 1900 revolutions per minute, at least 2000 revolutions per minute, at least 2100 revolutions per minute, at least 2200 revolutions per minute, at least 2300 revolutions per minute, at least 2400 revolutions per minute, or at least 2500 revolutions per minute. In some embodiments, each respective sanding board in the one or more sanding boards spins about the respective axis of the respective sanding board at the respective center of the respective sanding board at a constant rate. In some embodiments, each respective sanding board in the one or more diamond boards spins about the respective axis of the respective sanding board at the respective center of the respective sanding board at a variable rate.

In some embodiments, each respective sanding board 112 in the one or more diamond sanding boards is tubular (cylindrical) and has a diameter of between 2 and 20 inches. In some embodiments, each respective sanding board in the one or more sanding boards is tubular (cylindrical) and has a diameter of between 1 and 5 inches. In some embodiments, each respective sanding board in the one or more sanding boards is tubular (cylindrical) and has a diameter of between 1 and 10 inches. In some embodiments, each respective sanding board in the one or more sanding boards is tubular (cylindrical) and has a diameter of at least 1 inch, at least 2 inches, at least 3 inches, at least 4 inches, at least 5 inches, at least 6 inches, at least 7 inches, at least 8 inches, at least 9 inches, or at least 10 inches. In some embodiments, each respective sanding board in the one or more sanding boards is tubular (cylindrical) and has the same diameter.

In some embodiments, the one or more sanding boards comprises between 2 and 30 sanding boards. In some embodiments, the one or more sanding boards comprises between 1 and 10 sanding boards. In some embodiments, the one or more sanding boards comprises between 4 and 10 sanding boards. In some embodiments, the one or more sanding boards comprises at least 2 sanding boards, at least 3 sanding boards, at least 4 sanding boards, at least 5 sanding boards, at least 6 sanding boards, at least 7 sanding boards, at least 8 sanding boards, at least 9 sanding boards, at least 10 sanding boards, at least 25 sanding boards, at least 50 diamond sanding boards, at least 75 sanding boards, or at least 100 sanding boards.

In some embodiments, each respective surface of each sanding board 112 in the one or more sanding boards makes contact with the initial fabric at an angle between 0 and 150 degrees. In some embodiments, each respective sanding board of each sanding board in the one or more sanding boards makes contact with the initial fabric as it is passing through the abrader at an angle of at least 0 degrees, at least 20 degrees, at least 40 degrees, at least 60 degrees, at least 80 degrees, at least 100 degrees, at least 120 degrees, or at least 140 degrees. In some embodiments, each respective sanding board of at least a first set of sanding boards in the one or more sanding boards makes contact with the initial fabric at a first angle, and each respective sanding board of at least a second set of sanding boards in the one or more diamond sanding boards makes contact with the initial fabric at a second angle. In some embodiments, the first angle and the second angle are both between 1 and 150 degrees.

In some embodiments, the abrader (e.g., comprising the one or more sanding boards) applies a predetermined pressure to the initial fabric as the initial fabric is passed through the abrader at the first predetermined speed (e.g., the initial fabric is kept under tension during the abrading). In some embodiments, the predetermined pressure is between 1 and 10 pounds per square inch (psi). In some embodiments, the predetermined pressure is between 2 and 5 psi. In some embodiments, the predetermined pressure is at least 1 psi, at least 2 psi, at least 3 psi, at least 4 psi, at least 5 psi, at least 6 psi, at least 7 psi, at least 8 psi, at least 9 psi, or at least 10 psi. Referring to block 270, in some embodiments, the pressure is between 5 Kg/cm and 60 Kg/cm.

Referring to block 272, in some embodiments the fabric is passed through the abrader at a speed (first predetermined linear speed) of between 5 meters/minute and 100 meters per minute. Referring to block 274, in some embodiments the fabric is passed through the abrader at a speed (first predetermined linear speed) of between 5 meters/minute and 40 meters per minute. In some embodiments, the first predetermined linear speed is between 80 meters per minute and 100 meters per minute. In some embodiments, the first predetermined linear speed is between 80 meters per minute and 200 meters per minute. In some embodiments, the first predetermined linear speed is between 50 meters per minute and 300 meters per minute. In some embodiments, the first predetermined linear speed is at least 50 meters per minute, at least 60 meters per minute, at least 70 meters per minute, at least 80 meters per minute, at least 90 meters per minute, at least 100 meters per minute, at least 110 meters per minute, at least 120 meters per minute, at least 130 meters per minute, at least 140 meters per minute, at least 150 meters per minute, at least 160 meters per minute, at least 170 meters per minute, at least 180 meters per minute, at least 190 meters per minute, at least 200 meters per minute, at least 210 meters per minute, at least 220 meters per minute, at least 230 meters per minute, at least 240 meters per minute, at least 250 meters per minute, at least 260 meters per minute, at least 270 meters per minute, at least 280 meters per minute, at least 290 meters per minute, or at least 300 meters per minute. In some embodiments, the first predetermined linear speed is constant.

Referring to block 278 of FIG. 2F, in some embodiments each sanding board in the one or more sanding plates spins about the respective axis of the respective sanding board at the center of the respective sanding at a rate of between 1000 revolutions per minute and 3000 revolutions per minute. Referring to block 280, in some such embodiments, each respective sanding board in the one or more sanding boards spins is cylindrical and has a diameter of between 2 inches and 20 inches. Referring to block 282, in some embodiments, the surface of each sanding board in the one or more sanding boards is electroplated diamond having a specified Grit. Referring to block 284, in some embodiments the specified Grit is between Grit 150 and Grit 2400. Referring to block 286, in some embodiments the one or more sanding boards comprises between 10 and 30 sanding boards.

In some embodiments, the surface of each sanding board in the one or more sanding boards is electroplated diamond having a specified grit (e.g., having a predetermined grit score or grit value). In some embodiments, the specified grit is between grit 400 and grit 2400. In some embodiments, the specified grit is between grit 100 and grit 2400. In some embodiments, the specified grit is between grit 100 and grit 1000. In some embodiments, the specified grit is between grit 200 and grit 600. In some embodiments, the specified grit is between grit 100 and grit 400. In some embodiments, the specified grit is between grit 100 and grit 800. In some embodiments, the specified grit is at least grit 100, at least 120, at least grit 150, at least grit 180 grit at least grit 200, at least grit 220, at least grit 240, at least grit 280, at least grit 320, at least frit 360, at least grit 400, at least grit 500, at least grit 600, at least grit 800, at least grit 1200, at least grit 1000, at least grit 1500, or at least grit 2000.

Block 288.

Referring to block 216 of FIG. 2F, in some embodiments the method proceeds by washing the fabric with an ozone composition, thereby obtaining an ozone washed fabric. In some embodiments, ozone washing the pre-washed fabric comprises applying ozone to the pre-washed fabric in an enclosed container with rotary motion (e.g., a washing machine). In some embodiments, the ozone washing can be performed for example as described in JP Patent Application No. JP2005295193, filed on October, 2005, entitled “Cloth drier, washing machine, and washing machine with cloth drying function” which is hereby incorporated by reference in its entirety. In some embodiments, the ozone washing machine is a Jeanologia G2 Dynamic 200 or G2 Dynamic 235 ozone washing machine. See, for example, https://www.jeanologia.com/portfolio/g2-dynamic/, which is hereby incorporated by reference.

Referring to block 290, in some embodiments, the ozone washed fabric is denim. In some embodiments, the ozone washed fabric is another type of fabric.

Referring to block 292, in some embodiments, the ozone composition (e.g., for use in ozone washing) is between 5 g/Nm³ ozone and 100 g/Nm³ ozone. In some embodiments, the ozone composition is between 5 g/Nm³ ozone and 50 g/Nm³ ozone. In some embodiments, the ozone composition is between 5 g/Nm³ ozone and 20 g/Nm³ ozone. In some embodiments, the ozone composition is between 10 g/Nm³ ozone and 20 g/Nm³ ozone.

Referring to block 294 of FIG. 2F, in some embodiments the fabric has a width of between 40 centimeters and 400 centimeters. In some embodiments the fabric has a width of between 40 centimeters and 200 centimeters. In some embodiments the fabric has a width of between 40 centimeters and 100 centimeters. In some embodiments, the fabric has a length of between 1 meter and 500 meters, between 2 meters and 400 meters, between 3 meters and 300 meters, between 4 meters and 200 meters, or between 5 meters and 100 meters. In some embodiments, the fabric has a width of between 40 centimeters and 400 centimeters and a length of between 1 meter and 500 meters.

In some embodiments, the washed fabric has a width of between 80 centimeters and 400 centimeters. In some embodiments, the washed fabric has a width of between 80 centimeters and 200 centimeters. In some embodiments, the washed fabric has a width of between 100 centimeters and 200 centimeters. In some embodiments, the washed fabric has a width of between 40 centimeters and 400 centimeters. In some embodiments, the washed fabric has a width of between 40 centimeters and 100 centimeters. In some embodiments, the washed fabric has a width of between 40 centimeters and 80 centimeters.

Referring to block 298 of FIG. 2G, in some embodiments, the ozone washed fabric has a length of at least 50 meters.

Referring to block 300 of FIG. 2G, in some embodiments, the ozone washed fabric has a length of at least 100 meters.

In some embodiments, the washed fabric has a length of at least 50 meters. In some embodiments, the washed fabric has a length of at least 100 meters. In some embodiments, the washed fabric has a length of at least 10 meters, at least 20 meters, at least 30 meters, at least 40 meters, at least 50 meters, at least 60 meters, at least 70 meters, at least 80 meters, at least 90 meters, at least 100 meters, at least 150 meters, at least 200 meters, at least 300 meters, at least 400 meters, or at least 500 meters. In some embodiments, the washed fabric has a length of between 10 meters and 100 meters, between 50 meters and 100 meters, between 50 meters and 200 meters, between 100 meters and 1000 meters, between 500 meters and 5000 meters, or between 2500 meter and 5000 meters.

Referring to block 302 of FIG. 2G, in some embodiments, abrading and washing cause the pre-washed fabric to exhibit a predetermined amount of color fade relative to the initial fabric. In some embodiments, the specified grit for the surface of each sanding board in the one or more sanding boards is varied to produce differing amounts of color fade in the ozone washed fabric relative to the initial fabric. In some embodiments, the specified grit value is inversely proportional to the predetermined amount of color fade (e.g., a higher specified grit value causes a lower amount of color fade relative to the initial fabric).

In some embodiments (e.g., where the yarn comprising the plurality of textile fibers has been dyed with indigo dye), the predetermined amount of color fade causes the washed fabric to be one of dark indigo, medium indigo, or light indigo. In some embodiments, with reference to block 304 of FIG. 2G, the predetermined amount of color fade causes the washed fabric to have a CIELab L* value that is between 8 and 49, a CIELab a* value that is between −1.4 and 3.5, and a CIELab b* value that is between −10.50 and −1.20. Under the CIELab coordinate system, L* represents the degree of lightness. The attribute a* indicates the degree of redness and greenness (when a* increases, the redness of the sample increases, and vice versa). The attribute b* indicates the degree of yellowness and blueness (when b* increases, the yellowness increases, and vice versa). In some embodiments, the predetermined amount of color fade causes the washed fabric to have a CIELab L* value that is between 35 and 43, a CIELab a* value that is between −1.4 and 3.5, and a CIELab b* value that is between −10.50 and −6.00.

In some embodiments, other amounts of color fade are obtained (e.g., intermediate shades of color fade such as medium-dark indigo, medium-light indigo, etc.). In some embodiments (e.g., where the yarn has been dyed at least in part with indigo dye), the predetermined amount of color fade causes the washed fabric to be one of dark intensity, medium intensity, or light intensity.

Blocks 306-312.

Referring to block 306 of FIG. 2G, the method optionally proceeds by using the washed fabric to produce the article of clothing. Referring to block 308, in some embodiments, using the ozone washed fabric to produce the article of clothing comprises cutting, making, and trimming with the ozone washed fabric to form the article of clothing. Referring to block 310, in some embodiments, the article of clothing is a pair of denim jeans. Referring to block 312, in some embodiments, the article of clothing is a denim shirt, a denim dress, a denim skirt, or a denim handbag. In some embodiments, the article of clothing is any article of clothing known in the art.

Block 314-316.

With reference to block 314 of FIG. 2H, in some optional embodiments, the method further comprises agitation washing the article of clothing. In some embodiments, agitation washing the article of clothing serves to remove any impurities or dirt accumulated during the previous steps in the manufacturing process. With reference to block 316, in some embodiments, the agitation washing of the article of clothing comprises a sonic washing in a water bath.

Block 318.

With reference to block 318 of FIG. 2H, in some the method optionally comprising drying the article of clothing.

Blocks 320-324.

In some embodiments, the method further comprises patterning the article of clothing with a laser to produce one or more laser designs within the article of clothing. In some embodiments, the one or more laser designs within the article of clothing comprise distressed or worn-out effects. In some embodiments, the patterning is done before the agitation washing of the article of clothing. In some embodiments, the patterning is done after the agitation washing and the drying of the article of clothing (e.g., this is important for articles of clothing with high amounts of patterning—e.g., many worn-out effects). In some embodiments, a Jeanologia Flexi Pro, Twin Pro, or Compact is used to perform such patterning.

EXAMPLES Example 1

In this example, methods for processing denim fabric are described. In these examples, an initial fabric is abraded by passing the initial fabric through an NB-MATCHPOINT GMB diamondTec finishing machine. In so doing, the initial fabric is abraded into a pre-washed fabric with an abraded texture. For Example 1, three denim fabrics were selected. Abrading data for the three denim fabrics is detailed below in Tables 1, 2, and 3. As detailed in these tables, for each respective fabric of the three selected fabrics, four samples of the respective fabric were used. For three of the four samples of a respective fabric, different levels of fabric abrasion were performed on the samples with a NB-MATCHPOINT GMB diamondTec finishing machine, while the fourth sample of the respective fabric was retained with no abrasion as a reference standard control.

The NB-MATCHPOINT GMB diamondTec finishing machine settings are indicated in Tables 1, 2 and 3 below with speeds, pressures and direction of the peacher rollers. In these tables, DP2 stands for 220 diamondpeach grit, DP4 stands for 400 diamondpeach grit, and DP6 stands for 600 diamondpeach grit.

FIG. 9 provides a schematic diagram of the NB-MATCHPOINT GMB diamondTec abrader 900 for purposes of identifying sanding boards (902-1), 2 (902-2), 3 (902-3), and 4 (902-4), contact roller 1 (906-1), contact roller 2 (906-2), the fabric (910) that is being abraded, and the double transport rollers 914. Further in these tables, and referring to FIG. 9, machine speed, in units of meters/minute, is the speed at which fabric 910 is passing through the abrader 900. Further in these tables, grit 1 is the grit value of sanding board 902-1, grit 2 is the grit value of sanding board 902-2, grit 3 is the grit value of sanding board 902-3, and grit 4 is the grit value of sanding board 902-4. Further in these tables, RPM of roll 1 is the revolutions per minute of sanding board 902-1, RPM of roll 2 is the revolutions per minute of sanding board 902-2, RPM of roll 3 is the revolutions per minute of sanding board 902-3, and RPM of roll 4 is the revolutions per minute of sanding board 902-4. Further in these tables, the roller direction 1 through 4 indicate whether each respective sanding board 902 is rotating clockwise (with the direction of the fabric) or counterclockwise (against the direction of the fabric) from the perspective of FIG. 9. In Tables 1 through 3, “CO” stands for cotton, and “EL” stands for elastane, and “PEL” stands for polyester.

TABLE 1 Denim Fabric One Fabric One Sample (A) Sample (B) Sample (C) Sample (D) Fabric 90% CO/8% 90% CO/8% 90% CO/8% 90% CO/8% composition EL/2% Lycra EL/2% Lycra EL/2% Lycra EL/2% Lycra Fabric width 170 170 170 170 (cm) Grit 1 DP6 DP4 DP2 None Grit 2 DP6 DP4 DP2 None Grit 3 DP6 DP6 DP2 None Grit 4 DP6 DP6 DP2 None Roller Direction Clockwise Clockwise Clockwise None 1 (902-1) Roller Direction Counter- Counter- Counter- None 2 (902-2) clockwise clockwise clockwise Roller Direction Clockwise Clockwise Clockwise None 3 (902-3) Roller Direction Counter- Counter- Counter- None 4 (902-4) clockwise clockwise clockwise RPM of roll 1 1600 1600 1600 None (902-1) RPM of roll 2 1600 1600 1600 None (902-2) RPM of roll 3 1600 1600 1600 None (902-3) RPM of roll 4 1600 1600 1600 None (902-4) Pressure on 10 50 30 None contact roll 1 in units of Kg/cm (906-1) Pressure on 10 50 30 None contact roll 2 in units of Kg/cm (906-2) Machine Speed 20 20 20 None m/min Pull Tension 1.2 1.2 1.2 None

TABLE 2 Denim Fabric Two Fabric Two Sample (A) Sample (B) Sample (C) Sample (D) Fabric 90% CO/8% 90% CO/8% 90% CO/8% 90% CO/8% composition EL/2% Lycra EL/2% Lycra EL/2% Lycra EL/2% Lycra Fabric width 170 170 170 170 (cm) Grit 1 DP6 DP4 DP2 None Grit 2 DP6 DP4 DP2 None Grit 3 DP6 DP6 DP2 None Grit 4 DP6 DP6 DP2 None Roller Direction Clockwise Clockwise Clockwise None 1 (902-1) Roller Direction Counter- Counter- Counter- None 2 (902-2) clockwise clockwise clockwise Roller Direction Clockwise Clockwise Clockwise None 3 (902-3) Roller Direction Counter- Counter- Counter- None 4 (902-4) clockwise clockwise clockwise RPM of roll 1 1600 1600 1600 None (902-1) RPM of roll 2 1600 1600 1600 None (902-2) RPM of roll 3 1600 1600 1600 None (902-3) RPM of roll 4 1600 1600 1600 None (902-4) Pressure on 10 50 30 None contact roll 1 in units of Kg/cm (906-1) Pressure on 10 50 30 None contact roll 2 in units of Kg/cm (906-2) Machine Speed 20 20 20 None m/min Pull Tension 1.2 1.2 1.2 None

TABLE 3 Denim Fabric Three Fabric Three Sample (A) Sample (B) Sample (C) Sample (D) Fabric 85% CO/ 85% CO/ 85% CO/ 85% CO/ composition 13% PEL/ 13% PEL/ 13% PEL/ 13% PEL/ 2% Lycra 2% Lycra 2% Lycra 2% Lycra Fabric width (cm) 170   170   170   170 Grit 1 DP6 DP4 DP2 None Grit 2 DP6 DP4 DP2 None Grit 3 DP6 DP6 DP2 None Grit 4 DP6 DP6 DP2 None Roller Direction Clockwise Clockwise Clockwise None 1 (902-1) Roller Direction Counter- Counter- Counter- None 2 (902-2) clockwise clockwise clockwise Roller Direction Clockwise Clockwise Clockwise None 3 (902-3) Roller Direction Counter- Counter- Counter- None 4 (902-4) clockwise clockwise clockwise RPM of roll 1 1600   1600   1600    None (902-1) RPM of roll 2 1600   1600   1600    None (902-2) RPM of roll 3 1600   1600   1600    None (902-3) RPM of roll 4 1600   1600   1600    None (902-4) Pressure on 10  50  30  None contact roll 1 in units of Kg/cm (906-1) Pressure on 10  50  30  None contact roll 2 in units of Kg/cm (906-2) Machine Speed 20  20  20  None m/min Pull Tension  1.2  1.2   1.2 None

All fabrics were then all treated with Jeanologia G2 dynamic ozone to remove loose indigo at a rate of 40 m/min-5 g of ozone. All fabrics were then sewn into pant leg form as illustrated in FIG. 6. FIG. 6 illustrates how the coupling of abrasion followed by ozone washing creates denim that looks like it has been processed in garment laundry but has now been created in the fabric form. In FIG. 6, the fabrics running with line 602-1 correspond to fabric one of Table 1, where the individual samples of fabric 1 are labeled. In FIG. 6, the fabrics running with line 602-2 correspond to fabric two of Table 2, where the individual samples of fabric 2 are labeled. In FIG. 6, the fabrics running with line 602-3 correspond to fabric three of Table 3, where the individual samples of fabric 3 are labeled. For each sample, there are two pant legs illustrated in FIG. 6, a left hand one and right hand one, which have been subjected to the same treatment.

Example 2

This example illustrates garment trials with and without fabric abrasion.

FIG. 7 illustrates an unwashed garment that has not been subjected to fabric abrasion (left) and an unwashed garment that has been subjected to fabric abrasion (right).

To produce the garment on the right of FIG. 7, in this example, a denim initial fabric was abraded by passing the initial denim fabric through an NB-MATCHPOINT GMB diamondTec finishing machine. In so doing, the initial fabric is abraded into a pre-washed fabric with an abraded texture. The NB-MATCHPOINT GMB diamondTec settings for the machine are indicated in Tables 4 below with speeds, pressures and direction of rollers.

TABLE 4 Denim Fabric Four Fabric Four Sample Material Description 85% CO/13% PEL/2% Lycra Fabric width 170 Grit 1 DP6 Grit 2 DP6 Grit 3 DP6 Grit 4 DP6 Roller Direction 1 (902-1) Clockwise Roller Direction 2 (902-2) Counter-clockwise Roller Direction 3 (902-3) Clockwise Roller Direction 4 (902-4) Counter-clockwise RPM of roll 1 (901-1) 2000 RPM of roll 2 (902-2) 2000 RPM of roll 3 (902-3) 2000 RPM of roll 4 (902-4) 2000 Pressure on contact roll 1 25 Pressure on contact roll 2 25 Machine Speed m/min 20 Pull Tension 2.5

The denim was then treated with a Jeanologia G2 dynamic ozone washer to remove loose indigo using 20 g/Nm³ of ozone. The denim was then sewn into the garment illustrated in the right panel of FIG. 7. The left hand garment and the right hand garment of FIG. 7 were then washed to produce the respective left-hand garment (not abraded) and right-hand garment (pre-abraded) of FIG. 8. As is evident in FIG. 8, there is a substantial difference in the fading. The pre-abraded fabric washes down faster.

CONCLUSION

Plural instances may be provided for components, operations, or structures described herein as a single instance. Finally, boundaries between various components, operations, and data stores are somewhat arbitrary, and particular operations are illustrated in the context of specific illustrative configurations. Other allocations of functionality are envisioned and may fall within the scope of the implementation(s). In general, structures and functionality presented as separate components in the example configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements fall within the scope of the implementation(s).

It will also be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first subject could be termed a second subject, and, similarly, a second subject could be termed a first subject, without departing from the scope of the present disclosure. The first subject and the second subject are both subjects, but they are not the same subject.

The terminology used in the present disclosure is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

As used herein, the term “if” may be construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” may be construed to mean “upon determining” or “in response to determining” or “upon detecting (the stated condition or event)” or “in response to detecting (the stated condition or event),” depending on the context.

The foregoing description, for purposes of explanation, has been described with reference to specific implementations. However, the illustrative discussions above are not intended to be exhaustive or to limit the implementations to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The implementations were chosen and described in order to best explain the principles and their practical applications, to thereby enable others skilled in the art to best utilize the implementations and various implementations with various modifications as are suited to the particular use contemplated. 

1. A method for processing denim comprising: abrading an initial fabric by passing the initial fabric through an abrader at a first predetermined speed in a first direction, wherein the abrader comprises one or more sanding boards, wherein each respective sanding board in the one or more sanding boards has a respective surface that contacts the initial fabric while spinning about a respective axis at the respective center of the respective board during the abrading, thereby obtaining a pre-washed fabric with an abraded texture; and washing the pre-washed fabric with an ozone composition, thereby obtaining an ozone washed fabric.
 2. The method of claim 1, the method further comprising: using the ozone washed fabric to produce an article of clothing.
 3. The method of claim 1, wherein the ozone washed fabric is denim.
 4. The method of claim 1, the method further comprising, prior to the abrading: dyeing a yarn comprising a plurality of textile fibers with a blue dye by coating a surface of the yarn with the blue dye; and weaving the yarn to form the initial fabric.
 5. The method of claim 4, wherein the blue dye is an indigo dye or a sulphur dye.
 6. (canceled)
 7. The method of claim 4, wherein the plurality of textile fibers comprises cotton fibers.
 8. (canceled)
 9. (canceled)
 10. (canceled)
 11. (canceled)
 12. (canceled)
 13. (canceled)
 14. The method of claim 4, wherein the plurality of textile fibers is round, dog bone shaped, trilobal, multilobal, serrated, band, triangular, oval, or hollow shaped.
 15. The method of claim 4, wherein the plurality of textile fibers is blended fibers.
 16. The method of claim 4, wherein the plurality of textile fibers is cotton blended with lycra, polyester, lyocell, wool, flax, or hemp.
 17. The method of claim 4, wherein the plurality of textile fibers comprises Gossypium hirsutum cotton, Gossypium barbadense cotton, Gossypium arboreum cotton, or Gossypium herbaceum cotton.
 18. The method of claim 4, wherein the plurality of textile fibers have a length in the range of 10-65 mm, a fitness in the range of 1.2-2.8 dtex, a dry tenacity in the range of 1.9-3.1 cN/dtex, a dry breaking extension in the range of 7 percent to 10 percent, a moisture regain of about 8.5 percent, and/or a density of 1.5 to 1.54 g/cm³.
 19. (canceled)
 20. The method of claim 4, wherein the yarn is a denim warp yarn having a count of between Ne 4.0 and Ne 12.5.
 21. The method of claim 4, wherein the yarn is a denim warp yarn having a count of between Ne 12.5 and Ne 30.0.
 22. (canceled)
 23. The method of claim 4, where the yarn is a blend of X percent cotton and Y percent elastane, wherein X and Y sum to 100 percent and X is in the range of 50 percent to 99 percent.
 24. The method of claim 4, where the yarn is a blend of X percent cotton, Y percent elastane, and Z percent Lycra, wherein X, Y, and Z sum to 100 percent and X is in the range of 50 percent to 94 percent.
 25. The method of claim 4, where the yarn is a blend of X percent cotton, Y percent polyester, and Z percent Lycra, wherein X, Y, and Z sum to 100 percent and X is in the range of 50 percent to 94 percent.
 26. (canceled)
 27. (canceled)
 28. (canceled)
 29. (canceled)
 30. The method of claim 1, wherein each respective surface of each sanding board in the one or more sanding boards spins about the respective axis of the respective board at the center of the respective board at a rate of between 1000 revolutions per minute and 3000 revolutions per minute.
 31. The method of claim 1, wherein each respective sanding board in the one or more sanding boards is tubular and has a diameter of between 2 inches and 20 inches.
 32. The method of claim 1, wherein the first predetermined speed is between 5 meters per minute and 100 meters per minute.
 33. (canceled)
 34. The method of claim 1, wherein each respective surface of each sanding board in the one or more sanding board is electroplated diamond have a specified Grit, wherein the specified Grit is between Grit 150 and Grit
 2400. 35. (canceled)
 36. The method of claim 1, wherein the one or more sanding boards comprises between 2 and 10 sanding boards.
 37. The method of claim 1, wherein the abrading and washing cause the pre-washed fabric to exhibit a predetermined amount of color fade relative to the initial fabric.
 38. The method of claim 37, wherein the predetermined amount of color fade causes the ozone washed fabric to have a CIELab L* value that is between 8 and 49, a CIELab a* value that is between −1.4 and 3.5, and a CIELab b* value that is between −10.50 and −1.20.
 39. The method of claim 2, wherein the article of clothing is a pair of denim jeans.
 40. (canceled)
 41. The method of claim 1, wherein the ozone composition is between 5 g/Nm³ ozone and 100 g/Nm³ ozone.
 42. The method of claim 1, wherein the ozone washed fabric has a width of between 40 centimeters and 400 centimeters and a length of at least 50 meters.
 43. (canceled)
 44. (canceled)
 45. (canceled)
 46. The method of claim 2, wherein using the ozone washed fabric to produce the article of clothing comprises cutting, making, and trimming with the ozone washed fabric to form the article of clothing.
 47. The method of claim 2, the method further comprising: agitation washing the article of clothing, and drying the article of clothing.
 48. The method of claim 47, the method further comprising patterning the article of clothing with a laser to produce one or more laser designs within the article of clothing.
 49. (canceled)
 50. (canceled)
 51. (canceled)
 52. The method of claim 1, wherein the one or more sanding boards is a plurality of slat rollers, cylinder rollers, or a combination thereof, each roller in the plurality of slat rollers, cylinder rollers, or combination thereof, spins clockwise or counterclockwise with respect to the first direction, independent of a spin of all other sanding boards in the plurality of slat rollers, cylinder rollers, or a combination thereof; and the abrader further comprises a plurality of contact rolls that push the fabric against the plurality of slat rollers at a predetermined pressure, wherein the predetermined pressure is between 5 and 60 Kg/cm.
 53. (canceled) 